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        General >> Problems >> So Near,...yet so far!
        
(Message started by: DJWerkz on Dec 30th, 2005, 9:48pm)
Title: So Near,...yet so far!
Post by DJWerkz on Dec 30th, 2005, 9:48pm
Big thank you to HowieD for today ;)  He came out with his stud extractor to try and remove that spark plug body but unfortunately it is stuck so hard the next course of action is to remove the head.

I think that taking all matters into consideration, removing the head is probably wise at this point so we can see how much debris has fallen into the bore, understand why the spark plug threaded shank is stuck so fast and get the head checked for any thread damage.

We were so near to be up and running but now it's back to strip-down mode again :(

Head will be removed tomorrow, so watch this space for further updates.
Title: Re: So Near,...yet so far!
Post by music_master on Dec 30th, 2005, 10:01pm
hang in there dj it will be all good when finished m8 ;)
Title: Re: So Near,...yet so far!
Post by howiedintheplace on Dec 30th, 2005, 11:10pm
Hmm that broken plug is so tight only route now is for craig to remove the head.

I had a 3ft bar on it & for about 5 minutes it looked possible but then the extractor chewed up the plug so that was that. Must of been over 80 lbs of torque but still no joy.
Pity we couldn't get a impact driver on it :(

Why do people do spark plugs so tight ??? Only should be 15 - 20 lbs???????

Your luck must change soon craig, perhaps next week a lottery win ;D

Goodluck mate.
Title: Re: So Near,...yet so far!
Post by mr._floppy on Dec 30th, 2005, 11:31pm
No  consolation   I know ,   but  the opposite    was  true  when I  replaced my sparkers,  3 out of the 4    were  well   loose.

Finger tight and then a quarter  turn   is what I was taught   when  tightening  ( new ones )   up.
Title: Re: So Near,...yet so far!
Post by DJWerkz on Dec 31st, 2005, 7:44pm
Head is off, came off without any hiccups etc.

Had a couple of further attempts to remove the spark plug shank without success, will keep soaking it and trying over the rest of the weekend.

(Got your tool out OK HowieD ;) )
Title: Re: So Near,...yet so far!
Post by SaveTheNight on Dec 31st, 2005, 9:53pm
Oh dear Craig !! ... you're at it again mate !! .. did you try taking it out with the engine hot ? .. anyway too late now I guess ... only advice is that aluminium expands at about twice the rate of steel so you need to heat the head for about fifteen mins in front of a blow heater or something.. or drop it in boiling water and try then ..when its out Wurth do a great set of rethread plug inserts ..I personally think they are better than helicoils ..if you need the kit and tools I'll post it off to you ..let me know ok ... hope all is well and fair play to Dave who's there helping again I see ..
Title: Re: So Near,...yet so far!
Post by howiedintheplace on Jan 1st, 2006, 9:10am
Hmmm well all too late now but as bill said, before you broke it you could have run the engine to heat it up to aid removal of a tight plug ;)

I would have been tempted to run the engine on 5 cylinders to heat it up but of course your not sure what has gone down the bore, the unburnt fuel is not good for the CAT & it could damage your ignition, so not recommended.

Is the tool still biting ???

Soak it, heat it up & give it your best shot.
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 1st, 2006, 10:49am
No HowieD, your tool is no longer effective.  I have a slightly different stuf extractor bit that is conical and reverse spiral that I will try after I'v applied some heat, see if that works.
Title: Re: So Near,...yet so far!
Post by Mickey_2.9 on Jan 1st, 2006, 11:34pm
Now the head is off, if you still can't get it out is it worth taking it to a machine shop and get them to machine the remains of the plug out? It may save a lot of time and effort in the long run.
Title: Re: So Near,...yet so far!
Post by howiedintheplace on Jan 2nd, 2006, 12:11am
I think that is next on Craigs list ???
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 2nd, 2006, 12:19am
Machine shop is indeed the final thing on my list.  STN has suggested one more option in the mean time though so if my conical stud extractor together with applied heat does not work then I will try STN's suggestion.

After that it's,...hi-ho, hi-ho, it's off to the machine shop I go ;)
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 2nd, 2006, 3:28pm
Would you believe it, tried an E-Z out on the stud today and it snapped in the plug!

What is wrong with this plug, does it have some kind of demonic hold onto the head or something...must be a weak E-Z out too.

Anyway, got an appointment with the machine shop at 10am in the morning to see how much they want to get the plug and E-Z out from the head.  He was quoting £100 on the phone if it's a bad one.

:(
Title: Re: So Near,...yet so far!
Post by howiedintheplace on Jan 2nd, 2006, 6:52pm
Craig I would give up now & let the shop do it.
If they knacker your head then you have some come back ;)
Seems a bit steep to me but hey I am a cheap skate :)
Title: Re: So Near,...yet so far!
Post by Mickey_2.9 on Jan 2nd, 2006, 6:58pm

on 01/02/06 at 18:52:20, howiedintheplace wrote:
Craig I would give up now & let the shop do it.
If they knacker your head then you have some come back ;)
Seems a bit steep to me but hey I am a cheap skate :)


[] I think that sound exspensive, maybe they are just covering them selves until they see the job. Maybe worth getting a used head if they quote to much?
Good luck anyway Craig.
Title: Re: So Near,...yet so far!
Post by Highlander on Jan 2nd, 2006, 7:20pm
How much would a good second hand head cost??
Might be the cheaper option ;D
Title: Re: So Near,...yet so far!
Post by SaveTheNight on Jan 2nd, 2006, 9:22pm
all easy outs break Craig !! ..even snap on ones .. use a locking wheel nut remover and torque bar.. i'll send you one with the thread insert tool < if you haven't already used the machine shop .. try and let me know before I send them off only to find the engine shop has sorted it please .... STN
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 3rd, 2006, 11:33pm
Took the head to the machine shop today and he said because there is now an E-Z out stuck in the plug it has to be 'spark-eroded' out.  He said that he can remove everything so that no threads are damaged.

Will get the head back sometime this week and hopefully my brother-in-law will be fitting it on Saturday
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 5th, 2006, 2:41pm
Got the head back today and the plug is finally out!

Looks like the plan to get it re-fitted this Saturday is still on ;)
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 5th, 2006, 9:18pm
...slight change of plan, re-fitting the head tomorrow (Friday),...woo-hooo!
Title: Re: So Near,...yet so far!
Post by SaveTheNight on Jan 5th, 2006, 9:24pm
nice one Craig ! ...... STN
Title: Re: So Near,...yet so far!
Post by martin_rowe on Jan 6th, 2006, 8:57am
bet its running by now then
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 6th, 2006, 10:10am
Not yet, just waiting for my brother-in-law to make it over to do the job.

However, I was just inspecting the block (in the car) and noticed that one of the chain guides is very loose, you can wiggle it around it seems.

As you look at the engine from the front of the car I am refering to the right bank left chain guide.  The right chain guide is tight.

Do I have more problems or is this normal considering the level of strip-down on this side of the engine?
Title: Re: So Near,...yet so far!
Post by martin_rowe on Jan 6th, 2006, 10:32am
if its the blade that the tensioner acts on then it will be free to move into the chain, as you will have the tensioner removed to get the head off, I hope, dont forget tensioner will have to be re set befor fitting & then relesed (with allen key)to make it work.
Title: Re: So Near,...yet so far!
Post by DJWerkz on Jan 6th, 2006, 10:51am
Yes this is the blade and yes we did remove the tensioner.  My brother-in-law has now arrived and he thinks all is OK.
Title: Re: So Near,...yet so far!
Post by howiedintheplace on Jan 6th, 2006, 7:29pm
Won't be long now ;)

My tool arrived today, looks like you cleaned it, cheers :)


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